INJECTION PUMP TEST SPECIFICATIONS 096000-4890

MANUFACTURER TOYOTA
INJECTION PUMP 096000-489#
ENGINE TYPE 2L VE4/10F2200RND489
VEHICLE MODEL HILUX/ ROTATION Clockwise viewed from GOVERNOR TYPE All speed
4 RUNNER drive side
RATED VOLTAGE 12V INJECTION ORDER A-B-C-D INJECTION INTERVAL 90° ± 30'
Dimension KF (mm) 5.50 ± 0.10 Dimension MS (mm) 0.45 ± 0.10
Dimension K (mm) 3.30 ± 0.10 Dimension PS (mm) —
1. TEST CONDITIONS
Nozzle 093400-0540 (DN12SD12A) Feed Pressure 19.6 kPa ( 0.2 kgf/cm2)
Nozzle Opening Pressure 14.7 ± 0.5 MPa ( 150 ± 5 kgf/cm2) High Pressure Pipe Ø2 X Ø6 X 840 mm
Test Oil SAE J967 (ISO4113) Fuel Temperature 40 - 45 °C (104 - 113°F)
NOTE : Apply 6 volts DC across the fuel cut solenoid during adjustment.
2. PRE-ADJUSTMENT
Lever Position Pump Speed Absolute Pressure Fuel Delivery Max. Spread
in Delivery
(deg) (rpm)
(kPa) (mmHg) (mm3/st) (cc/200st) (mm3) (cc)

Full Load 28 ± 5° 1200 101.3 ± 0.2 760.0 ± 1.5 52.9 ± 0.5 10.6 ± 0.1 2.0 0.4
(Full)
High Speed 2450 101.3 ± 0.2 760.0 ± 1.5 24.0 ± 2.5 4.8 ± 0.5 — —
3. ADJUSTMENT OF INTERNAL PRESSURE
Lever Position Pump Speed Absolute Pressure Internal Pressure Remarks
(rpm) (kPa) (mmHg) (kPa) (kgf/cm2)

Full 500 101.3 ± 0.2 760.0 ± 1.5 343.0 ± 29.0 3.5 ± 0.3 By the regulating valve

2100 101.3 ± 0.2 760.0 ± 1.5 677.0 ± 29.0 6.9 ± 0.3

4. OVERFLOW QUANTITY CHECK

Lever Position Pump Speed Absolute Pressure Overflow Quantity Remarks
(rpm) (kPa) (mmHg) (L/h) (cc/1000st)
Full 2200 101.3 ± 0.2 760.0 ± 1.5 22 - 48 167 - 364
NOTE : The overflow valve belonging to the pump should be used checking.
5. ADJUSTMENT OF TIMER
Lever Position Pump Speed Absolute Pressure Piston Travel Remarks
(rpm) (kPa) (mmHg) (mm)

Full 800 101.3 ± 0.2 760.0 ± 1.5 1.10 ± 0.40

1200 101.3 ± 0.2 760.0 ± 1.5 2.50 ± 0.40

2000 101.3 ± 0.2 760.0 ± 1.5 5.30 ± 0.40

2300 101.3 ± 0.2 760.0 ± 1.5 6.10 ± 0.24

NOTE : Hysteresis at each pump speed is less than 0.3 mm.

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6. ADJUSTMENT OF DAC

Lever Pump Absolute Pressure Fuel Delivery Max. Spread Remarks

Speed in Delivery
Position
(rpm) (kPa) (mmHg) (mm3/st) (cc/200st) (mm3) (cc)

Full 1200 101.3 ± 0.2 760.0 ± 1.5 52.9 ± 0.5 10.6 ± 0.1 2.0 0.4

1200 90.7 ± 0.2 680.0 ± 1.5 50.9 ± 1.0 10.2 ± 0.2 — —

1200 70.7 ± 0.2 530.0 ± 1.5 43.4 ± 1.5 8.7 ± 0.3 — —

7. ADJUSTMENT OF FUEL DELIVERY

Lever Pump Absolute Pressure Fuel Delivery Max. Spread Remarks

Speed in Delivery
Position
(rpm) (kPa) (mmHg) (mm3/st) (cc/200st) (mm3) (cc)

Full 1200 101.3 ± 0.2 760.0 ± 1.5 52.9 ± 0.5 10.6 ± 0.1 2.0 0.4 By full load setting screw

2450 101.3 ± 0.2 760.0 ± 1.5 24.0 ± 2.5 4.8 ± 0.5 — — By max. speed setting screw

2250 101.3 ± 0.2 760.0 ± 1.5 42.3 ± 3.0 8.5 ± 0.6 — —

Less than Less than
2700 101.3 ± 0.2 760.0 ± 1.5 5.0 1.0 — —

100 101.3 ± 0.2 760.0 ± 1.5 65.0 ± 10.0 13.0 ± 2.0 6.0 1.2 By governor sleeve plug

500 101.3 ± 0.2 760.0 ± 1.5 49.1 ± 2.0 9.8 ± 0.4 2.5 0.5

2100 101.3 ± 0.2 760.0 ± 1.5 47.0 ± 1.8 9.4 ± 0.4 2.5 0.5

8. SETTING OF LOAD SENSING TIMER — : Not Applicable

Lever Position Pump Speed Absolute Pressure Fuel Delivery Remarks
(rpm) (kPa) (mmHg) (mm3/st) (cc/200st)

Start of Load Sensing — — — — — —

End of Pressure Drop — — — — — —

Check Points 1. — : — mm

2. Dimension of Governor Shaft : L = 1.15 ± 0.85 mm

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9. SETTING OF ADJUSTING LEVER AT LOW SPEED
Lever Pump Absolute Fuel Delivery Max. Spread Remarks
Position Speed in Delivery
(deg) (rpm) (kPa) (mm3/st) (cc/500st) (mm3) (cc)

– 16 ± 5° 350 101.3 ± 0.2 17.4 ± 1.5 = A 8.7 ± 0.8 = A 1.7 0.9 Lever setting
(760.0 ± 1.5 mmHg)
(Idle)
425 101.3 ± 0.2 (A – 10.8) ± 2.5 (A – 5.4) ± 1.3 — —
(760.0 ± 1.5 mmHg)

10. SETTING OF ADJUSTING LEVER AT PARTIAL RANGE — : Not Applicable

Pump Speed Absolute Pressure Fuel Delivery Remarks
3
(rpm) (kPa) (mmHg) (mm /st) (cc/500st)

— — — — — —

11. CHARACTERISTIC OF A.C.S.D. — : Not Applicable

Lever Position Pump Speed Absolute Pressure Measuring Value Remarks
(rpm) (kPa) (mmHg)
— — — — — —

Fuel temperature : 39 - 41°C

12. ADJUSTMENT OF T.C.V. — : Not Applicable
Lever Position Pump Speed Absolute Pressure Piston Travel Remarks
(rpm) (kPa) (mmHg) (mm)
— — — — — —

13. SETTING OF DIAPHRAGM FOR HEATER & POWER STEERING — : Not Applicable

Pump Speed Vacuum Pressure Fuel Delivery Remarks

3
(rpm) (kPa) (mmHg) (mm /st) (cc/500st)
— — — — — —

14. ADJUSTMENT OF POWER CONTROL — : Not Applicable

Lever Position Pump Speed Boost Pressure Fuel Delivery Remarks
3
(rpm) (kPa) (mmHg) (mm /st) (cc/200st)
— — — — — — —
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15. ADJUSTMENT OF THROTTLE POSITION SENSOR — : Not Applicable

Lever Position Pump Speed Absolute Pressure Fuel Delivery Sensor Remarks
Output
(rpm) (kPa) (mmHg) (mm3/st) (cc/500st) Voltage (V)

— — — — — — — —

16. FINAL CHECK AFTER ADJUSTMENT

1. Range of lever angle between idle and full lever position is 44.5 ± 3°.
2. Resistance of pick-up tachometer must be 650 - 1020 ohms {20 - 40 °C (68 - 104 °F)}.
3. After adgustment has been completed, delivery quantity must be 0 mm3/st (0 cc/200st)
when voltage at fuel cut solenoid is reduced to zero. (Pump Speed Np = 100 rpm)